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Relationship between steel mass loss and accelerated corrosion regimes in

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Relationship between steel mass loss and accelerated corrosion

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

Relationship between steel mass loss and accelerated corrosion

regimes in reinforced concrete columns
Mushtaq Sadiq Radhi 1,-Maan S. Hassan 2 ,-Iqbal N. Gorgis 2
1
Department-of Civil Engineering, -College of Engineering, University of-Kerbala,-Kerbala, Iraq
2
Civil- Engineering-Dept., University of-Technology, -10066, -Baghdad, -Iraq.

E-mail: mushtaq.sadiq@uokerbala.edu.iq

Abstract. Present study aims to observe the consequence of varying the intensity of
the accelerating impressed electrical current and situations of wetting-drying as hybrid
accelerated corrosion regime on synthetically corroded concrete specimens, especially
the loss of steel mass. Small-scaled reinforced concrete columns were fabricated and
synthetically corroded by altered accelerating corrosion situations by applying an
impressed current with intensity ranging between (50 and 500 µA/cm2). Moreover, the
impressed current joined with two dissimilar durations of wetting- drying cycles for
assessment. The steel mass losses during and at the end of the accelerated corrosion
process were calculated, also, cracking configuration and damage shape were observed
for accelerating corrosion. The outcomes designated that the hybrid method
(impressed current joined with cycles of saline solution wetting and drying series) can
be employed adequately to simulate the regular corrosion process in the reinforced
concrete structure. The steel mass loss is mostly influenced by the intensities of the
impressed accelerating current, while the crack appearance and the pattern of surface
cracks, is influenced by wetting and drying cycles as well as the impressed
accelerating current. Yet, increasing the current intensity produce a considerable
growth in the cracking owing to the reinforcing steel corrosion in shorter stage.

1. Introduction
Steel corrosion in every situation is an electro-chemical process wherein Fe (iron) is eliminated from
the corroded steel, dissolving within the nearby solution, to form Fe + (ferrous ions). Intended for
embedded steel in concrete structures, the dissolving activity occur in the bounded quantity of water
solution existing in the concrete pores neighboring the steel. The dissolving ions (Fe+) in the pore
solutions of concrete generally rejoin with the ions of hydroxide (OH2) and dissolved particles of
oxygen (O2) to create one or a combination of numerous kinds of rust, namely as a solid byproduct of
the reaction of corrosion. The rust is typically precipitated on the boundary of the reinforcement steel
bars and the concrete. It’s formation within this constrained space leads to cracking in the concrete
cover due to the extensive stresses. These cracks take place above the steel reinforcing bars and
arrange in a line with them, this is associated to a severe durability distress [1]–[3].

Natural steel corrosion is extremely slow, requiring more than (10 years) to make severe structural
damage. For example, Zhang et al [4]–[6] allowed the laboratory reinforced concrete specimens to
corrode naturally, they were required to wait for more than (4 years) for steel corrosion to being and
an additional (two years) for the appearance of first cracking .It required 20 years to reach the level of
dangerous structural damage. Many efforts were done to practice numerous regimes to accelerate the
corrosion of embedded steel in concrete for attempting to shrink the time that required for tests.
Numerous literatures have been specified on acceleration the corrosion process in reinforced concrete

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IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

using Galvano-Static Method (otherwise known as Impressed Current System) joined with solution of
saline. El Maaddawy et al [7], carried out an experimentation on full-scaled reinforced concrete beams
that were affected by attacks of the chloride at altered intervals of subjecting a constant impressed
current at density of (215 mA). The results revealed that the average steel mass loss fluctuated around
(8.9 % to 31.6%). Though, the width of maximum cracks varied from (0.9 to 2.9) mm at subjecting
periods ranging between (50 to 310 days) correspondingly. Malumbela et al. [8], examined a different
strength full-scaled reinforced concrete beams put under (5% NaCl) solution wetting and drying cycles
to accelerate the embedded steel corrosion. An impressed constant current of density (189,µA/cm2)
was applied. A 0.04 mm crack width in the reinforced concrete due to corrosion products caused by
(1%) steel mass loss. Similarly in the other experimental investigation accomplished by Elghazy et
al.[9], approved a comparable process for accelerating steel corrosion with (180 µA/cm2) impressed
current and (5% NaCl) solution of identical cycles of wetting and drying were employed in the
reinforced steel bars. Wang et al. [10], experimentally examined the corrosion effect on reinforced
concrete slabs by impressing of a constant current of (50-200 µA/cm2) with different arrangements
(half soaking in solution of (5% NaCl), full soaking in solution of (5% NaCl), and wet dry cycling). It
was found that the applicable manner of accelerated corrosion was governed by the goal of the
research. The small impressed current with the cycles of wetting and drying process and half soaking
were selected if study was on corroded steel rebar reinforcement itself, whereas, if research was on the
bond between corroded steel reinforcement and the damaged concrete or expansive rusts products that
led to the concrete cover cracking, wet dry cycles with a slight impressed accelerating current is used.
However, the partial soaking accelerating corrosion manner (soaking up to two-third of the height of
the specimen in saline solution with concentration of 3.5 %) with great impressed accelerating current
at (1Am) to achieve the expansive products that form the cracks in corroded specimens have been
nominated in the another research directed by Kashi et al.[11] .

Kearsley and Joyce [12] employed great impressed current with regular intensity of (1087 μA/cm2)
and fully soaked reinforced concrete specimens in (5%, NaCl) solution for accelerating of the process
of steel corrosion. Furthermore, Sanz et al [13], designated impressed current regime using great
constant current concentration of (400 µA/cm2) and fully soaked specimens in CaCl solution for
accelerating the loss of bonding concerning the reinforcement steel bar and concrete. Kashani et al.
[14], inspected the performance of steel reinforcement bars through corrosion process and they
accomplished noticeable corrosion rate by applying (1100 – 2400 µA/cm2) with complete soaking in
(3% NaCl) solution. Even though, Pritzl et al. [15], implemented accelerated corrosion approach by
applying little impressed current concentration at series between ( 30 and 45 µA/cm2) joined (6%
NaCl) solution wetting and drying cycles .

Previously local studies, Al-Galawi et al.[16], employed the impressed current accelerating
corrosion method so as to achieve simulating exposure intervals equivalent of (5 and 25 years) regular
exposure of corrosion situations and the applied current concentrations of (50-100 μA). Besides,
further local experimental investigation on embedded steel accelerated corrosion by Hassan [17] ,
studied the influence of a ( 600 µA/cm2) impressing current to accelerate the steel reinforcing bars
corrosion on reinforced concrete beams. The author reaches steel mass loss of 26% afterward (60
days) from beginning the accelerating corrosion practice. Regardless of various investigations being
presented in the accelerated steel corrosion regime for, there are no identical Standard specification
ways for accelerating corrosion of the embedded steel on laboratory reinforced concrete samples.
Therefore, it necessitates further investigations for recognizing the applicable arrangements for
accelerating corrosion in the research laboratory experiments that make appropriate simulation of the
ordinary corrosion of embedded steel in the reinforced concrete. The reinforced concrete columns
comprising columns in marine structure, reinforced concrete piles, and highways bridges columns, are
more relevant structural elements, which are mostly susceptible for embedded steel corrosion owing to
subjecting for the moisture and severe environment, producing dangerous drops in the capacity of the

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

load transport and structural reliability of the elements. In the existing research work, six small-scaled
reinforced columns were synthetically corroded by applying altered impressed accelerating current
arrangements joined with two sorts of wetting and drying cycles of the saline solution demanding to
realize the variances among them, from the steel mass loss stand point, finally to conclude the most
suitable.

2. Constituents and experimental works

A total of six small-scaled circular reinforced concrete columns (100 mm diameter and 300 mm
height) were considered with altered patterns of accelerating corrosion. The identified cube concrete
strength at 28 days age was 40 MPa (about 32 MPa for cylinder).

2.1 Constituents
This subdivision reviews the properties of reinforced concrete production and constituents were
utilized in the existing study including cement, aggregate, and reinforcing bars. Al-Jeser karbala high
sulfate-resistance cement was utilized in fabrication concrete compatible to ASTM-C150. Tables (1)
and (2) display the properties of utilized cement. Al-Ukhaider Karbala natural sand was utilized as fine
aggregate compatible to ASTM-33, with 2.93 fineness modulus and 0.3 sulfate content. Al-Nebai
black crushed gravel was used as coarse aggregate compatible to ASTM-C33, with 9.5 mm maximum
and 0.07 sulfate content. 6 mm diameter deformed bars and 4 mm diameter plain bars were used for
the main and spiral stirrup reinforcements, respectively. The used steel bars meeting the requirements
of ASTM A-1064. The approved concrete mix proportion was (1: cement 1.75 sand: 3.5 gravel) and
the water-to-cement ratio 0.38, the mix for plain concrete was designed agreeing to ACI 211. Figure
(1) displays the details of the reinforced column. Tap water was utilized for curing the reinforced
specimens for 28 days.

2.2 Accelerating corrosion regimes

Previously, researchers have utilized exterior impressed electrical current methods for accelerating the
steel bars corrosion in reinforced concrete. The basic principle of applying the external D.C. electrical
current is quite easy and comprises of forming an electrochemical circuit via an exterior D.C. power
source. In an electric cell, the steel bars in reinforced concrete play as an anode and another material
plays as the cathode [18][19]. After tap water curing for 28 days, the reinforced concrete circular
columns were plunged in a solution of NaCl (3.5% salt concentration) for 3 days to eliminate passivity
of steel bars, then, the columns were enclosed in a mesh of stainless-steel, the gap between columns
and stainless-steel mesh was filled by sponge material. A constant current was supplied between the
anode (reinforcing bars in the columns) and the cathode (exterior stainless-steel mesh) from a D.C.
power device. The applied currents were 500, 200, and 50 μA/cm2. The wetting- drying cycles of the
NaCl solution, with concentration of 3.5%, were combined with impressed current. Two arrangements
of cycles were implemented, half of the reinforced columns were subjected to wetting for 1 day
followed by drying for a 3 day and the remaining columns were subjected to wetting for 1 day
followed by drying for 6 days. In the drying days, the impressed current was turned-off and the
columns were taken away and exposed to room air for drying days. Table (3) demonstrates the details
of accelerated corrosion regimes for all the reinforced circular columns in the present study. The
arrangements of the regimes of acceleration corrosion process were as described in Radhi et. al. [20].
The corroded reinforced columns were discovered twice for each day. The current of corrosion and
surface cracking were detected over the phase of accelerated corrosion to conclude the amount of steel
loss; the scale of damage caused by rusts and the cracks pattern.

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

Table 1. Chemical characteristics for the utilized cement.

Oxide composition Abbreviation %-by weight Parameters of ASTM 150
Lime CaO 62.52 -
Silica SiO2 21.85 -
Alumina Al2O3 3.86 -
Iron oxide Fe2O3 4.67 -
Sulphate SO3 1.68 ≤ 2.3%
Magnesia MgO 1.58 ≤ 6%
Loss on Ignition L.O.I. 0.93 ≤ 3%
Lime saturation factor L.S.F. 0.97 0.66-1.02
Insoluble residue I.R. 0.70 ≤ 0.75
Main compounds (Bogues eq.) % by weight of cement
Tricalcium silicate (C3S) 51.05
Diacalcium silicate (C2S) 24.14
Tricalcium aluminate (C3A) 2.31
Tetracalcium aluminoferrite. (C4AF) 14.2

Table 2. Physical characteristics for the utilized cement.

Physical properties Test result Parameters of ASTM 150
Specific surface area, Blaine 305 >260
Method, (m2/kg).
Setting time
(Vicat,s method)
-Initial setting(min.) 200 ≥ 45 min.
-Final setting (min.) 290 ≤ 375 min.
Compressive strength
(MPa):
3-days 30.5 ≥ 15
7-days 37.5 ≥ 21

Figure 1. Reinforced columns information.

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

Table 3. The accelerated corrosion regimes for each sample.

Column current Wetting and Drying series
Description Intensity μA/cm2
C050W3D 50 1 days Wetting -3 days Drying
C050W6D 50 1 days Wetting -6 days Drying
C200W3D 200 1 days Wetting -3 days Drying
C200W6D 200 1 days Wetting -6 days Drying
C500W3D 500 1 days Wetting -3 days Drying
C500W6D 500 1 days Wetting -6 days Drying

2.3 Steel mass loss

Many earlier researchers have effectively employed the Faraday’s law to theoretically calculate steel
mass loss or estimat the required time for acquiring a specific level of corrosion in the reinforced
concrete samples. In the current study, the Faraday’s law was adopted to estimate the steel mass loss
due to the steel corrosion process from the accelerated regimes in the corroded reinforced columns
based on the impressed current density, Faraday’s law as follow (eq. 1) [21]:
$ .'.(
∆𝑚 = ) .*.
(1)
Where:
(∆𝑚) theoretical steel mass loss caused by the accelerated corrosion regime, (𝑀) is the steel molar
mass which about 56 g, (𝑖) is the impressed accelerated corrosion regime in Am. (𝑡) is the required
time for corrosion in second. (𝐹) is the Faraday’s law constant 96500 A/s, (𝑍) is the ionic charge in
iron equal 2.

3. Discussion of results
The succeeding subdivisions display the outcomes acquired after about 90 days of accelerated steel
corrosion for the six columns. Steel loss, observable first crack appearance and cracks configuration
were adopted as indicators for steel corrosion damage. Table 4 summarizes the observation of the steel
corrosion in the current study.

Table (4) the outcomes of the steel corrosion in all RC columns.

Column Theoretical Steel mass loss % observable first surface

Description cracks
Cumulative Per cycles Duration Total of
(Days) cycles
C050W3D 2.55 0.127 --- 20
C050W6D 1.27 0.127 --- 10
C200W3D 9.72 0.511 76 19
C200W6D 4.60 0.511 63 9
C500W3D 10.84 1.204 36 9
C500W3D 4.82 1.204 28 4

3.1Steel mass loss and observable cracks

Steel mass losses were determined by applying Faraday’s Law (mentioned earlier). In using this
equation the effectiveness of the impressed current was supposed to be 100% indicating that all the
impressed current was distributed to each specimen. Investigations by previous researchers have also
revealed that steel mass loss assessed by applying Faraday’s Law appeared to overestimate the real
steel mass loss. [22] et al. stated the overestimation of steel mass loss by Faraday’s law associated
with real steel mass loss. They found that the alteration between the actual steel mass loss and the

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

theoretical steel mass loss depend on the applied voltage and concrete cover. Although, all the
corroded columns detected similar shape of damage and cracking pattern, which side observable
surface cracks equivalent to the main column reinforcement bar direction, as shown in figures (2) and
(3). While, as mentioned earlier in table 4, the observable first surface crack for the columns
C200W3D and C200W6D acquired on steel mass loss percent 9.72 % and 4.64% at 76 and 63 days
respectively. The observable first surface crack for the columns C500W3D and C500W6D acquired on
steel mass loss percent 10.84 % and 4.82% at 36 and 28 days individually, as shown in figure (4). This
tendency in the variation of steel mass loss fo attaining the observable cracks may be attributed to the
alteration in rust compounds depending on available oxygen and moisture besides the impressed
current density, as identified by [21]. On the contrary, at the end of the accelerated steel corrosion the
steel mass loss percent for the columns C050W3D and C050W6D are 2.55% and 1.204% without any
observable first surface crack, and may acquire the observable first surface crack, depending on
Faraday’s Law, after 320 days and 279 days, respectively.

Figure 2. The observable crack in Figure 3. The damage pattern in the columns.
column.

80
observable first cracks time

70
60
50
40
(days)

30
20
10
0
3D

6D

3D

6D

3D

6D
W

W
50

50

00

00

00

00
C0

C0

C2

C2

C5

C5

columns description

Figure 4. the cracks appearance time in the all colmns.

3.2 Steel mass loss and accelerated corrosion regime

As stated earlier in experimental part in this study the hybrid accelerated steel corrosion regime was
adopted, which that intersection between the impressed current technique (three current density, 50,
200, and 500 μA/cm2) and wetting drying cycles system (1 day wetting -3days wetting and 1 day

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BCEE4 IOP Publishing
IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

wetting-6 days wetting). As stated in table 6, the outcomes revealed that the impressed current
increased the rate of steel mass loss increases. The steel mass loss percentage for 500, 200, and 50
μA/cm2 are 1.204%, 0.511, and 0.127 % per wetting drying cycle, respectively. Although, the effect of
each impressed current density equal for steel mass loss in the different wetting- drying system, but the
rate of the damage in the concrete columns was somewhat different. This trend may be attributed to
the different rust products volumes depending on the availability of oxygen in the 1 wetting-6 drying
cycle more than 1wetting-3 drying cycle.

4. Conclusions
The correlation between the steel mass loss and altering the accelerating impressed current for
corrosion of reinforced concrete columns specimens was examined. The study evaluated the steel mass
loss applying Faraday’s Law, observable first crack appearance and cracks configuration. The
succeeding leading findings from this experimental study are:
1- For the corroded reinforced concrete columns, the steel mass loss depend mainly on the impressed
current density, and the rate of steel mass loss increases noticeably with an increase in the
impressed current density.
2- Intended for the corroded reinforced concrete columns, the damage rate and observable first crack
appearance depend on the type of rusts produced as well as the impressed current density.
3- Changing the wetting drying cycles, has no influence on the steel mass loss of corroded reinforced
concrete columns, but effect on the corrosion products nature, the higher drying period the higher in
the size of the corrosion produced.
4- The type of the accelerated corrosion regime has no influence on the damage shape and cracks
pattern. For all corroded columns, the observable surface cracks were equivalent to the steel
reinforcing bars unrelatedly of the wetting and drying cycles or the subjected impressed current
level.
5- Reduction in the required time of the appearance of the observable first crack on the corroded
reinforced columns with increasein the density of the impressed current in accelerated corrosion
regimes.
6- The hybrid accelerated steel corrosion regime by joining the impressed current with alternative
drying wetting process is recognized to be an operative method to inspect the growth of the
corrosion of steel bars in the reinforced concrete buildings, and its impacts of the cover damage in
concrete element.

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IOP Conf. Series: Materials Science and Engineering 737 (2020) 012051 doi:10.1088/1757-899X/737/1/012051

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